Ergonomic torch regulator controller

ABSTRACT

A torch assembly adapted to be attached to an associated fuel supply, the torch assembly has a housing, a fuel line at least partially contained within the housing, a burn tube extending from the housing and adapted to receive fuel from the fuel line, an attachment member operatively connected to the housing for connecting the torch assembly to the associated fuel supply, the attachment member in fluid communication with the fuel line for delivering fuel from the associated fuel supply to the fuel line; a control apparatus having a trigger for actuating an on/off valve adapted to permit or stop flow through the fuel line, a regulator adapted to at least partially restrict flow in the fuel line, and a controller operatively connected to the regulator to adjust the position of the regulator to vary the flow of fuel through the fuel line.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/245,225, filed Sep. 26, 2011 (allowed), which claims priority to U.S.Provisional Application Ser. No. 61/386,668 filed Sep. 27, 2010, thedisclosures of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present exemplary embodiment relates generally to a torch designthat provides control of a flame, and more particularly to an ergonomiccontroller of a flame regulator. However, it is to be appreciated thatthe present exemplary embodiment is also amenable to other likeapplications.

BACKGROUND OF THE INVENTION

Torches are used in various applications for applying localized intenseheat. One such application is pipe soldering. Pipe soldering involvesjoining together components such as two pipes or fittings through theapplication of solder to the joint. To flow solder into the joint, atorch is used to heat the joint and/or solder directly until the solderreaches its melting point. Once the solder becomes a liquid, it thenflows into the joint and, upon cooling, joins and seals the componentstogether.

It will be appreciated that controlled application of heat to the jointis often desirable. A user of a conventional torch can control theapplication of heat by moving the torch into and out of proximity to thejoint such that the joint experiences intermittent heating until adesired level of heating is achieved. Another way to manage theapplication of heat is through adjusting the size of the torch flame.Soldering a pipe, however, typically requires a person to use a firsthand to hold the torch and a second hand to hold the solder. To safelyadjust the torch flame, a user must set down the solder and use thesecond hand to manipulate a knob or other device configured to controlthe flame. This can be inconvenient and can decrease worker efficiency.Moreover, a user may be tempted to adjust the flame without setting downthe solder which can present a safety hazard.

SUMMARY OF THE INVENTION

Embodiments described herein allow the user to hold the torch and adjustthe flame with the same (single) hand during operation, such as during asoldering operation, thus eliminating the need for the user to set thesolder down to adjust the flame, and/or reducing unsafe conditions thatmay exist should a user attempt to adjust the flame without setting downthe solder. More generally, aspects of the disclosure provide a moreuser friendly torch designed for single handed operation.

In accordance with one aspect, a torch assembly adapted to be attachedto an associated fuel supply comprises a housing, a fuel line at leastpartially contained within the housing, a burn tube extending from thehousing and adapted to receive fuel from the fuel line, an attachmentmember operatively connected to the housing for connecting the torchassembly to a fuel supply, the attachment member in fluid communicationwith the fuel line for delivering fuel from the associated fuel supplyto the fuel line, and a control apparatus at least partially supportedwithin the housing and configured to control the flow of fuel throughthe fuel line. The control apparatus includes a trigger for actuating anon/off valve adapted to permit or stop flow through the fuel line, aregulator adapted to at least partially restrict flow in the fuel line,and a controller operatively connected to the regulator to adjust theposition of the regulator to vary the flow of fuel through the fuelline. The controller is interposed between the trigger and theregulator.

The controller can include a rotatably mounted knob. The housing caninclude a lower pistol grip portion having a contoured gripping surfaceand an upper portion including the trigger, and the rotatably mountedknob can be disposed between the trigger and the lower pistol gripportion of the housing. The position of the knob can permit operation ofthe controller with a person's hand while the hand is gripping the lowerpistol grip portion of the housing. The trigger can be located in spacedrelation to a longitudinal axis of the lower pistol grip portion of thehousing, and the knob can be located between the longitudinal axis ofthe lower pistol grip portion of the housing and the trigger. Theregulator can include a regulator valve. The knob can be coextensivewith at least a portion of the lower pistol grip portion of the housing.The lower pistol grip portion can be adapted to fit in a person's hand,wherein the trigger is adapted to be activated by the person's triggerfinger, and wherein the knob is positioned to be manipulated by theperson's thumb.

The knob can be rotatable about an axis generally perpendicular to alongitudinal axis of the lower pistol grip portion of the housing. Theknob can be supported within the housing and can protrude from at leasttwo sides of the housing such as, for example, opposite sides of thehousing. The regulator can include a piston type regulator. The assemblycan further include a trigger lock operative to lock the on/off valve inan on position. An igniter can be operably connected to the trigger.

In accordance with another aspect, a control apparatus for an associatedtorch assembly comprises a trigger for actuating an on/off valve adaptedto permit or stop flow of fuel through a fuel line of the associatedtorch assembly, a regulator adapted to at least partially restrict flowin the fuel line of the associated torch assembly and including aregulator valve, and a controller operatively connected to the regulatorto adjust the position of the regulator valve to vary the flow of fuelthrough the fuel line of the associated torch assembly. The controlleris interposed between the trigger and the regulator.

The controller can include a rotatably mounted knob. The regulator caninclude a piston type regulator. A trigger lock operative to lock theon/off valve in an on position can be provided. The regulator, regulatorvalve and/or on/off valve can be included in a common valve body. Thecontrol apparatus can be installed as a unit in the associated torchassembly. An igniter can be operably connected to the trigger.

The invention relates to a torch assembly adapted to be attached to anassociated fuel supply, the torch assembly comprising a housing, a fuelline at least partially contained within the housing, a burn tubeextending from the housing and adapted to receive fuel from the fuelline, an attachment member operatively connected to the housing forconnecting the torch assembly to the associated fuel supply, theattachment member in fluid communication with the fuel line fordelivering fuel from the associated fuel supply to the fuel line, acontrol apparatus having a trigger for actuating an on/off valve adaptedto permit or stop flow through the fuel line, a regulator adapted to atleast partially restrict flow in the fuel line, and a controlleroperatively connected to the regulator to adjust the position of theregulator to vary the flow of fuel through the fuel line, and whereinthe control apparatus is at least partially supported within the housingand configured to control the flow of fuel through the fuel line;wherein the controller is interposed between the trigger and theregulator; wherein the housing includes a lower pistol grip portionhaving a contoured gripping surface and an upper portion including thetrigger; wherein the trigger is located in spaced relation to alongitudinal axis of the lower pistol grip portion of the housing; andwherein the position of the controller permits operation of thecontroller with a person's hand while the hand is gripping the lowerpistol grip portion of the housing.

The invention also relates to a control apparatus for an associatedtorch assembly comprising a trigger for actuating an on/off valveadapted to permit or stop flow of fuel through a fuel line of theassociated torch assembly, a regulator adapted to at least partiallyrestrict flow in the fuel line of the associated torch assembly andincluding a regulator valve, a controller operatively connected to theregulator to adjust the position of the regulator valve to vary the flowof fuel through the fuel line of the associated torch assembly, andwherein the controller is interposed between the trigger and theregulator; wherein the housing includes a lower pistol grip portionhaving a contoured gripping surface and an upper portion including thetrigger, wherein the trigger is located in spaced relation to alongitudinal axis of the lower pistol grip portion of the housing, andwherein the position of the controller permits operation of thecontroller with a person's hand while the hand is gripping the lowerpistol grip portion of the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of an exemplary torch assembly inaccordance with the disclosure;

FIG. 2 is a side elevation view of the torch assembly of FIG. 1 withportions thereof removed to expose otherwise concealed components;

FIG. 3 is a cross-sectional view of the torch assembly of FIG. 1;

FIG. 4 is a perspective view of an exemplary integrated regulator/valvebody in accordance with the disclosure;

FIG. 5 is a cross-sectional view of the integrated regulator/valve bodyof FIG. 4;

FIG. 6 is a perspective view of the integrated regulator/valve bodyincluding the outer knob;

FIG. 7 is a cross-sectional view of the integrated regulator/valve bodyof FIG. 6;

FIG. 8 is a front elevational view of the integrated regulator/valvebody;

FIG. 9 is a perspective view of an exemplary regulator block inaccordance with the disclosure;

FIG. 10 is an assembly view of the integrated regulator/valve body andintake stem in accordance with the disclosure;

FIG. 11 is an assembly view of the valve components of the regulatorvalve;

FIG. 12 is an exploded view of at least some of the on/off valvecomponents;

FIG. 13 is another view of the regulator block illustrating installationof a seal screw;

FIG. 14 is a perspective view of the regulator block and intake stem inaccordance with the exemplary embodiment;

FIG. 15 is a perspective assembly view of the installation of the knobon the regulator block;

FIG. 16 is a perspective view of the knob installed on the regulatorblock.

DETAILED DESCRIPTION

An exemplary embodiment of a torch assembly 20 in accordance with thepresent disclosure is shown in FIGS. 1-3 and includes a housing 22 madeof die cast metal such as steel, or plastic, to form a handle. Thehousing 22 includes a lower pistol grip portion G configured to begrasped by a user. The grip portion G may have a suitable profile so asto comfortably fit within a palm of a user's hand. The housing 22 alsoincludes an upper portion U that includes a trigger 26 and a controlknob 28 for adjusting the flow of fuel through the torch assembly tocontrol the torch flame. A burn tube 24 extends upwardly from thehousing 22. These components are visible on the exterior of the torchassembly 20 as shown in FIG. 1.

FIGS. 2 and 3 show the internals of the torch assembly 20 in perspectiveand partial cross-section views, respectively. As will be appreciated,the torch assembly is configured to be attached to a gas cylinder tankor other source of fuel. Gas, such as propane or propylene, is deliveredfrom the tank (not shown) located beneath the housing 22. An attachmentmember, in this case a threaded bushing 30, which may be, for example, aCGA 600 bushing, allows an empty tank to be removed and replaced with afull tank. Alternatively, a quick connect coupler could be used toprovide more a rapid tank exchange.

The housing 22 may be provided in two halves 22 a that mate to enclosemany of the components of the torch assembly including the bushing 30,an integrated valve and regulator body 32, an on/off valve 34, aregulator 36, a trigger assembly 38, an intake stem assembly 40, anorifice adapter 42 for connection to the burn tube 24, a continuous runlock button 93, and a trigger lockout button 94. FIGS. 3 and 12 show theon/off valve, which includes a valve core 44, spring 46, o-ring 48,actuator 50, and snap ring 52. To release fuel into the burn tube 24,the valve 34 is actuated by pushing the trigger 26. When the trigger 26is depressed, the valve 34 is opened to allow the fuel to flow into theburn tube 24 under pressure, subject to any restriction to flow providedby the regulator 36. The spring 46 returns the valve 34 to the closedposition and the trigger 26 to the extended position when the trigger 26is released.

The trigger assembly 38 includes an igniter 54, which may be, forexample, a piezoelectric igniter that is also actuated by the trigger26. When the trigger 26 is depressed a spark is created in the burn tube24 simultaneously with, or just after, the flow of gas through the burntube 24. Trigger lockout button lock 94 is provided to mechanically lockthe trigger 26 in the depressed position to allow “hands free” operationof the torch 20 such that the torch 20 will produce a flame without theuser having to continually depress the trigger 26.

The intake stem assembly 40 is provided at the lower end of the housing22. An extension tube 95 of the intake stem assembly 40 is brazed orotherwise connected to the integrated valve and regulator body 32 at theregulator input 56 and to the bushing 30 as shown in FIG. 10. The intakestem 58 is mounted to the bushing 30 with an O-ring 60, a filter 62, anda gasket 66.

The regulator 36, which is a piston-type valve in the embodiment shown,controls the flow of gas through a fuel supply line 68. The regulatorincludes a valve assembly disposed in the integrated valve and regulatorbody 32. FIG. 11 shows that the regulator 36 includes a valve core 72,an O-ring 74, a piston 76, a spring 78, a bonnet 80, and a jam nut 82. Alubricant, such as a silicon-based lubricant, may be applied to theo-ring 74, for example, silicone lubricants offered by 3M®, Molykote®offered by Dow Corning®, Krytox® offered by Loctite®, and anti-siezelubricants offered by Loctite®. The regulator 36 and the on/off valve 34may be the same type of valves as shown, or may be different types andsizes of valve as selected by one of ordinary skill in the art.

At one end 81 of the bonnet 80, which has a larger diameter than thebody of the bonnet 80, external threads are provided. At the largeopening 83 of the regulator body 32, internal threads are provided. Thebonnet 80 is screwed into the regulator body opening 83. The bonnet'sthreading interfaces with the regulator body's threading to determinethe spring 78 position. The spring position applies force on the piston76 through compression. This force applied to the piston determines thepressure of the internal gas required to open the valve 72. The jam nut82 is passed over the bonnet 80 and the smaller end 85 of the jam nut 82is screwed into the regulator body opening 83 to prevent withdrawal ofthe bonnet 80 from the regulator body 32.

As shown in FIGS. 6-8, 15, and 16, in one embodiment a splined collar 84is press fitted around the bonnet 80 of the regulator 36, which has aknurled outer surface. A knob 86 is slid over the splined collar 84 andis exposed through an aperture 88 (FIG. 1 and FIG. 3) in one or bothsides of the housing 22. The knob 86 may be, for example, plastic orbrass. When the knob 86 is rotated, most likely with a person's thumband forefinger, the splined collar 84 rotates and the bonnet 80 turnswith the splined collar 84. The knob 86, splined collar 84, and bonnet80 actuate the regulator valve. When the bonnet 80 rotates in onedirection, the piston 76 of the regulator 36 is pressed to open thevalve, and when the bonnet 80 rotates in the other direction, the pistonwithdraws, allowing the valve to close. If desired, the valve could beconfigured to close when pressed. There is a small spring (not visible)in the valve 72 that provides return force to the piston 76. Theposition of the knob 86 along its axis of rotation A_(k) is heldconstant, while the splined collar 84 travels within the knob 86 alongthe axis A_(k) and the bonnet 80 travels with the splined collar 84. Thedegree to which the valve is open corresponds to the position of thesplined collar and bonnet.

The orifice adapter 42 may be configured to work with ½-inch thin walltubing and brass venturis, and may allow burn tube-installed and otherorifices.

Turning back to FIG. 1, it will be appreciated that in the illustratedembodiment the knob 28 is rotatable about the axis A_(k) extending fromleft to right. This axis is generally perpendicular to a longitudinalaxis A_(g) of the lower pistol grip portion G of the housing 22. Inaddition, it will be observed that the trigger 26 is located forward ofthe longitudinal axis A_(g) of the lower piston grip portion G, with theknob 28 being between the trigger 26 and such axis. In this embodiment,the knob 28 is coextensive with the lower pistol grip portion G of thehousing and set slightly forward of said longitudinal axis A_(g). Inthis position, the knob 28 is easily accessible to a finger of aperson's hand while holding the torch.

One embodiment of a method of manufacturing the on/off valve 34 andregulator 36 is shown in FIGS. 9-16. The integrated valve and regulatorbody 32, or the regulator block, is shown in FIG. 9. FIGS. 10 and 14show the installation of the intake stem assembly 40 and parts to sealto the bushing 30 as described above. FIG. 11 shows the assembly of theregulator 36, as described above. FIG. 12 shows the assembly of theon/off valve 34, also as described above. A seal screw 90 is installedin FIG. 13.

In FIG. 15 the splined collar 84 is added over the bonnet 80 and theouter knob 86 is added over the splined collar 84. The assembledintegrated valve and regulator is shown in FIG. 16, with the orificeassembly 92, and the burn tube 24 may be installed as shown in FIG. 1.

The integrated valve and regulator body may instead be provided as twoseparate components, one for the on/off valve and one for the regulator.

Putting a rotating knob or wheel between the trigger and regulatorprovides an ergonomic location for an adjustment device for the flame.Locations other than that shown for the adjustment device could be usedand remain within the spirit and scope of the ergonomic torch regulatorcontrol knob described herein. The described piston regulator foradjusting the pressure of the gas improves control over the flame ascompared to the traditional needle valve flow restrictor, though thetraditional valve and arrangement could be used.

The exemplary embodiment has been described with reference to thepreferred embodiments. Obviously, modifications and alterations willoccur to others upon reading and understanding the preceding detaileddescription. It is intended that the exemplary embodiment be construedas including all such modifications and alterations insofar as they comewithin the scope of the appended claims or the equivalents thereof.

What is claimed is:
 1. A torch assembly adapted to be attached to anassociated fuel supply, the torch assembly comprising: a) a housing; b)a fuel line at least partially contained within the housing; c) a burntube extending from the housing and adapted to receive fuel from thefuel line; d) an attachment member operatively connected to the housingfor connecting the torch assembly to the associated fuel supply, theattachment member in fluid communication with the fuel line fordelivering fuel from the associated fuel supply to the fuel line; e) acontrol apparatus having a trigger for actuating an on/off valve adaptedto permit or stop flow through the fuel line, a regulator adapted to atleast partially restrict flow in the fuel line, and a controlleroperatively connected to the regulator to adjust the position of theregulator to vary the flow of fuel through the fuel line; and f) whereinthe control apparatus is at least partially supported within the housingand configured to control the flow of fuel through the fuel line;wherein the controller is interposed between the trigger and theregulator; wherein the housing includes a lower pistol grip portionhaving a contoured gripping surface and an upper portion including thetrigger; wherein the trigger is located in spaced relation to alongitudinal axis of the lower pistol grip portion of the housing; andwherein the position of the controller permits operation of thecontroller with a person's hand while the hand is gripping the lowerpistol grip portion of the housing.
 2. A torch assembly as set forth inclaim 1, wherein the controller includes a rotatably mounted knob.
 3. Atorch assembly as set forth in claim 1, wherein the controller iscoextensive with at least a portion of the lower pistol grip portion ofthe housing.
 4. A torch assembly as set forth in claim 1, wherein thelower pistol grip portion is adapted to fit in a person's hand, whereinthe trigger is adapted to be activated by the person's trigger finger,and wherein the controller is positioned to be manipulated by theperson's thumb.
 5. A torch assembly as set forth in claim 2, wherein theknob is rotatable about an axis generally perpendicular to alongitudinal axis of the lower pistol grip portion of the housing.
 6. Atorch assembly as set forth in claim 2, wherein the knob is supportedwithin the housing and protrudes from at least two sides of the housing.7. A torch assembly as set forth in claim 2, wherein the knob protrudesfrom opposite sides of the housing.
 8. A torch assembly as set forth inclaim 1, wherein the regulator includes a piston regulator.
 9. A torchassembly as set forth in claim 1, further comprising a trigger lockoperative to lock the on/off valve in an on position.
 10. A torchassembly as set forth in claim 1, wherein the regulator includes aregulator valve.
 11. A torch assembly as set forth in claim 1, furtherincluding an igniter operably connected to the trigger.
 12. A controlapparatus for an associated torch assembly comprising: a) a trigger foractuating an on/off valve adapted to permit or stop flow of fuel througha fuel line of the associated torch assembly; b) a regulator adapted toat least partially restrict flow in the fuel line of the associatedtorch assembly and including a regulator valve; c) a controlleroperatively connected to the regulator to adjust the position of theregulator valve to vary the flow of fuel through the fuel line of theassociated torch assembly; and d) wherein the controller is interposedbetween the trigger and the regulator; wherein the housing includes alower pistol grip portion having a contoured gripping surface and anupper portion including the trigger, wherein the trigger is located inspaced relation to a longitudinal axis of the lower pistol grip portionof the housing, and wherein the position of the controller permitsoperation of the controller with a person's hand while the hand isgripping the lower pistol grip portion of the housing.
 13. A controlapparatus as set forth in claim 12, wherein the regulator includes apiston regulator.
 14. A control apparatus as set forth in claim 12,further comprising a trigger lock operative to lock the on/off valve inan on position.
 15. A control apparatus as set forth in claim 12,wherein the regulator and regulator valve are housed in a common valvebody.
 16. A control apparatus as set forth in claim 12, wherein theregulator, regulator valve, and on/off valve are housed in a commonvalve body.
 17. A control apparatus as set forth in claim 12, whereinthe controller includes a rotatably mounted knob.
 18. A controlapparatus as set forth in claim 12, further including an igniteroperably connected to the trigger.